Double inlet blower wheel

ABSTRACT

A double inlet blower wheel has a plurality of blades having at least one notch. A center disk has an outer diameter and a plurality of slots disposed about a circumference. The slots extend inwardly from the outer diameter of the center disk. The center disk has roll-over tabs for each of the slots, wherein each of the blades engages a respective one of the slots. The plurality of blades are fully encapsulated about a periphery, where an edge of the blades defines a blower wheel outer diameter, where the outer diameter of the center disk is less than the blower wheel outer diameter. A support disk is coupled to a central region of the center disk, providing a greater thickness of the center disk and adds rigidity to the center disk. A pair of inlet rings also respectively secures opposing ends of each of said plurality of blades.

REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/281,893 filed Jan. 22, 2016, entitled “DOUBLE INLET BLOWER WHEEL”, the contents of which are herein incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates generally to a blower wheel, and more specifically to a double inlet blower wheel and method for forming a blower wheel.

BACKGROUND

Many types of blower wheels are known in the art, where one type, called a double inlet blower wheel, is operable to draw a gas (e.g., air) from opposing ends the blower wheel and to expel the gas radially. One example blower wheel 10 is illustrated in FIGS. 1A-1B, where the blower wheel comprises a plurality of fan blades 12 that are positioned about a circumference 14 of the blower wheel, wherein a hub 16 or center disk is provided along an axis 18 of the blower wheel between open ends 20 thereof, thus providing opposing inlets 22, 24 of the blower wheel when associated with a rotation of the blower wheel within a housing (not shown).

The plurality of blades 12 are secured at each inlet ring 26, 28 by a tab 30 extending from the ends 31 of the blades. Each tab 30 protrudes through a slot 32 in the ring 26, 28 and is then hammered down to form a rivet cap 33, thus fully securing the end 31 of each blade 12 to the respective ring 26, 28. The center disk 16 is typically a singular embossed metal disk with slots 34 configured to allow the respective blades 12 to pass therethrough. The blades 12 are further slotted (not shown) where they pass through the slots 34 in the center disk 16 in order to act as an interlock with an inner diameter 36 and a region 38 for roll-over tabs (not shown) of the center disk 16 to flow on an outer diameter 42 of the center disk. Once the roll-over tabs 40 are fully displaced and rolled over on the center disk 16, the blades 12 are fully secured to the center disk.

Conventionally, the outer diameter 42 of the hub or center disk 16 is generally greater than the circumference 14 of the blower wheel 10. Mechanical strength of fastening of the blades 12 to the center disk 16 has traditionally been troublesome, whereby the center disk has been traditionally quite thick in order to provide strength and rigidity. Further, the outer diameter 42 of the center disk is traditionally larger than a blade outer diameter 44 of the blower wheel 10 due to the provision of the roll-over tabs 40, whereby material usage associated with the conventional blower wheels 10 has been high.

SUMMARY

The present disclosure provides an innovative double-inlet blower wheel having an increased mechanical strength of fastening of blades to a center disk over conventional blower wheels, while also reducing material content associated with the center disk. The present disclosure thus provides a double inlet blower wheel and method for forming a blower wheel. Accordingly, the following presents a simplified summary of the disclosure in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.

In accordance with one aspect of the disclosure, a double inlet blower wheel is provided comprising a plurality of blades, wherein each of the plurality of blades has at least one notch defined along a length thereof. A center disk of the blower wheel has an outer diameter, wherein a plurality of slots are defined in the center disk and are disposed about a circumference thereof. The plurality of slots extend a predetermined distance inwardly from the outer diameter of the center disk.

According to one exemplary aspect, the at least one notch of each of the plurality of blades engages a respective one of said plurality of slots, wherein the center disk fully encapsulates each of the plurality of blades about a periphery of each of the plurality of blades. Further, an edge of the plurality of blades defines a blower wheel outer diameter, wherein the outer diameter of the center disk is less than the blower wheel outer diameter. A pair of inlet rings further respectively securing opposing ends of each of said plurality of blades thereto.

In one example, the plurality of slots are equally spaced about a circumference of the center disk. In another example, the plurality of blades are curved when viewed from an axis of rotation of the blower wheel.

In accordance with another example, the center disk further comprises a support disk operably coupled to a central region thereof. The support disk, for example, provides a greater thickness of the center disk in the central region than at a periphery of the center disk, wherein the support disk increases a rigidity of the center disk.

The center disk, for example, comprises a plurality of roll-over tabs respectively associated with each of the plurality of slots. The plurality of roll-over tabs are configured to respectively encapsulate the plurality of blades about the periphery thereof. In one example, the at least one notch in each of the plurality of blades comprises a V-shaped notch centered along the length thereof.

In another example, the plurality of slots further define an inner diameter of the center disk. Each of the plurality of blades, for example, further has a clearance notch, wherein the clearance notch generally opposes the V-shaped notch. The clearance notch of each of the plurality of blades, for example, engages the inner diameter of the center disk. Further, in another example, the plurality of roll-over tabs are configured to respectively engage the V-shaped notch of each of the plurality of blades. In one example, the clearance notch is rectangular.

To the accomplishment of the foregoing and related ends, the disclosure comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate front and side perspective views of a conventional blower wheel.

FIG. 2A illustrates a side perspective view of an exemplary blower wheel of the present disclosure.

FIG. 2B is a front plan view of the exemplary blower wheel of FIG. 2A.

FIG. 2C is a blown up portion of the exemplary blower wheel of FIG. 2D.

FIG. 2D is a perspective cross section of a portion of the blower wheel of FIG. 2A.

FIG. 3 is a perspective view of a center disk according to another exemplary aspect of the disclosure.

FIG. 4A is a plan view of a center disk according to another exemplary aspect of the disclosure.

FIG. 4B is a side cross-sectional view of the exemplary center disk of FIG. 4A.

FIG. 4C is a blown up portion of the exemplary center disk of FIG. 4A.

FIG. 4D is a plan view of another center disk according to another exemplary aspect of the disclosure.

FIG. 5 is a perspective view of a blade according to another exemplary aspect of the disclosure.

FIG. 6A is a plan view of a blade according to another exemplary aspect of the disclosure.

FIG. 6B is a blown up portion of the exemplary blade of FIG. 6A.

FIG. 6C is another blown up portion of the exemplary blade of FIG. 6A.

FIG. 6D is yet another blown up portion of the exemplary blade of FIG. 6A.

FIG. 6E is rotated view of the exemplary blade of FIG. 6A.

FIG. 6F is side cross-sectional view of the exemplary blade of FIG. 6E.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure is directed generally toward a double inlet blower wheel and a system, apparatus, and method for forming a double inlet blower wheel.

Accordingly, the present invention will now be described with reference to the drawings, wherein like reference numerals may be used to refer to like elements throughout. It is to be understood that the description of these aspects are merely illustrative and that they should not be interpreted in a limiting sense. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident to one skilled in the art, however, that the present invention may be practiced without these specific details. Further, the scope of the invention is not intended to be limited by the embodiments or examples described hereinafter with reference to the accompanying drawings, but is intended to be only limited by the appended claims and equivalents thereof.

It is also noted that the drawings are provided to give an illustration of some aspects of embodiments of the present disclosure and therefore are to be regarded as schematic only. In particular, the elements shown in the drawings are not necessarily to scale with each other, and the placement of various elements in the drawings is chosen to provide a clear understanding of the respective embodiment and is not to be construed as necessarily being a representation of the actual relative locations of the various components in implementations according to an embodiment of the invention. Furthermore, the features of the various embodiments and examples described herein may be combined with each other unless specifically noted otherwise.

It is also to be understood that in the following description, any direct connection or coupling between functional blocks, devices, components, circuit elements or other physical or functional units shown in the drawings or described herein could also be implemented by an indirect connection or coupling. Furthermore, it is to be appreciated that functional blocks or units shown in the drawings may be implemented as separate features or circuits in one embodiment, and may also or alternatively be fully or partially implemented in a common feature or circuit in another embodiment.

FIGS. 2A-2D illustrate various views of an exemplary blower wheel 100 in accordance with one aspect of the present disclosure, wherein the blower wheel is configured to provide advantageously higher rotational speed, lighter weight, and reduced material cost and usage as compared to the blower wheel 10 of FIGS. 1A-1B. The blower wheel 100 of FIGS. 2A-2B, for example, comprises a plurality of blades 102 that are positioned about a circumference 104 of the blower wheel. A center disk 106 is provided along an axis 108 of the blower wheel 100 between open ends 110 thereof, wherein the center disk is generally solid. The center disk 106, for example, may comprise a hub 115, wherein the hub is configured to selectively couple the blower wheel 100 to a shaft of a motor (not shown) for rotationally driving the blower wheel. The center disk 106, for example, further defines opposing inlets 112, 114 of the blower wheel when associated with a rotation of the blower wheel within a housing (not shown).

The plurality of blades 102, for example, are secured at ends 116 thereof to a pair of inlet rings 118, 120. In one example, the plurality of blades 102 are secured to the pair of inlet rings 118, 120 by a tab 122 (e.g., illustrated in blown-up view 123 in FIG. 6D) extending from the ends 116 of each blade 102. The tab 122, for example, protrudes through a slot 124 in the ring 118, 120 and is then hammered down to form a rivet cap thus fully securing the blade to the respective inlet ring 118, 120.

In accordance with one example, the center disk 106 is illustrated in FIG. 3, whereby the center disk is formed (e.g., stamped) from a sheet of material (not shown) having a reduced thickness compared to the center disk 16 of FIGS. 1A-1B. The center disk 106 of FIGS. 2A, 2D, and 3, for example, comprises an embossed design 126, wherein the center disk maximizes a strength associated with the reduced thickness thereof, and whereby the center disk efficiently transfers a dynamic load from the blades 102 of FIGS. 2A-2D to the hub 115 of the blower wheel 100 upon rotation thereof.

The center disk 106 illustrated in FIGS. 3 and 4A-4D, for example, comprises a plurality of slots 128, whereby the plurality of blades 102 of FIGS. 2A-2D are configured to reside within the respective plurality of slots. The center disk 106, for example, has an outer diameter 130, wherein the plurality of slots 128 are defined in the center disk and are disposed about a circumference 132 thereof, as illustrated in FIG. 4A. FIG. 4B illustrates a cross-section 133 of the center disk 106 of FIG. 4A. The plurality of slots 128, for example, extend a predetermined distance inwardly from the outer diameter 130 of the center disk 106.

The plurality of blades 102 of FIGS. 2A-2D, for example, are substantially similar to one another, whereby each of the plurality of blades, for example, may be viewed as the exemplary blade 102 shown in FIGS. 5 and 6A-6F. The plurality of blades 102, for example, an example of which is shown in FIG. 6E, are curved when viewed from the axis 118 of the blower wheel 100 of FIG. 2A, as further illustrated in cross-section 131 of FIG. 6F. In one example, each of the plurality of blades 102 comprises at least one notch 132, whereby the plurality of blades are configured to reside in the plurality of slots 128 in the center disk 106 of FIGS. 3 and 4A-4D. Accordingly, the at least one notch 132 of each of the plurality of blades 102 engages a respective one of the plurality of slots 128 of the center disk 106 of the blower wheel 100 of FIGS. 2A-2D.

In accordance with the present disclosure, the center disk 106 if FIG. 2D fully encapsulates each of the plurality of blades 102 about a periphery 134 of each of the plurality of blades, as illustrated in blown up portion 135 shown in FIG. 2C. For example, the center disk 106 comprises a plurality of roll-over tabs 136, as illustrated in greater detail in blown up view 137 shown in FIG. 4C, whereby the plurality of roll-over tabs are respectively associated with each of the plurality of slots 128. The plurality of roll-over tabs 136, for example, are configured to respectively encapsulate the plurality of blades 102 of FIG. 2C about the periphery 134 thereof after a rolling operation, whereby the roll-over tabs are compressed or flowed on the outer diameter 130 of the center disk 106.

Thus, when rolled over on an outer diameter 130 of the center disk 106, the roll-over tabs 136 thereby act as an interlock and secure the plurality of blades 102 to the center disk. In accordance with one exemplary aspect of the disclosure, upon rolling of the roll-over tabs 136, the center disk 106 fully encapsulates each of the plurality of blades 102, thereby permitting greater rotational speeds of the blower wheel 100 than previously seen in conventional blower wheels. By fully encapsulating the periphery 134 of the plurality of blades 102 via the roll-over tabs 136, structural integrity of the blower wheel 100 is improved while minimizing weight and material costs associated with the center disk 106.

Accordingly, in the present example, an outer edge 138 of the plurality of blades 102 illustrated in FIGS. 2B-2C thus defines a blower wheel outer diameter 140, whereby the outer diameter 142 of the center disk 106 is advantageously less than the blower wheel outer diameter. Such a sizing of the center disk 106 advantageously reduces material costs, as less material is needed for stamping of the center disk.

Further, according to another example, an inner edge 144 of each of the plurality of blades 102 of FIG. 5, for example, is configured to rest on an inner diameter 146 of the center disk 106 (e.g., the end of the slot 128) of FIGS. 3 and 4A-4D defined by the plurality of slots 128 in the center disk 106. In one example, the at least one notch 132 in each of the plurality of blades 102 comprises one or more of a clearance notch 148, as illustrated in blown up view 149 in FIG. 6C, and a V-shaped notch 150, as illustrated in blown up view 151 in FIG. 6B. The clearance notch 148, for example, generally opposes a V-shaped notch 150, wherein the clearance notch of each of the plurality of blades 102 is configured to engage the inner diameter 146 of the center disk 106, and wherein the plurality of roll-over tabs 136 of FIG. 4C, for example, are configured to respectively the V-shaped notch.

According to another example, the at least one notch 132 (e.g., comprising one or more of the V-shaped notch 150 clearance notch 148) is configured to accommodate a reduced diameter of the center disk 106 over conventional blower wheels, whereby the at least one notch is further configured to mechanically locate the center disk 106 in parallel position to the rings 118, 120. Accordingly, the present disclosure provides a reduced cost double inlet blower wheel 100 with reduced mass and equal or better air flow characteristics to previous designs.

In accordance with yet another example, a support disk 148 is further provided to strengthen the center disk 106 in central region 150 thereof, as illustrated in FIG. 2D. The support disk 148, for example, provides a greater thickness of the center disk 106 in the central region 150 than at a periphery 152 of the center disk associated with the plurality of blades 102, whereby the support disk substantially increases a rigidity of the center disk. Thus, the support disk 148 may be provided to achieve a predetermined maximum speed associated with the size of the blower wheel 100 of FIGS. 2A-2D.

As such, the outer diameter 130 of the center disk 106 is advantageously reduced over the conventional designs in order to reduce material usage associated with the size of the center disk. The support disk 148 of FIG. 2D, for example, may be staked, welded, or otherwise coupled to the center disk 106, whereby the thinner material associated with the center disk is advantageously strengthened and supported in the central region 150 within the inner diameter 146 of the center disk, thus allowing for the thinner material to be used in the formation of the remainder of the center disk.

Furthermore, the outer diameter 130 of the center disk 106 illustrated in FIG. 4A, for example, is less than the outer edge 138 of the plurality of blades 102 defining the blower wheel outer diameter 140. By providing such a smaller outer diameter 130 of the center disk 106, material savings may be attained over conventional blower wheels. For example, the center disk 106 may be stamped from a square sheet metal blank, where the area of the square sheet metal blank is advantageously smaller than conventional blanks, since the outer diameter 130 is smaller in accordance with the present disclosure.

Although the invention has been shown and described with respect to a certain embodiment or embodiments, it should be noted that the above-described embodiments serve only as examples for implementations of some embodiments of the present invention, and the application of the present invention is not restricted to these embodiments. In particular regard to the various functions performed by the above described components (assemblies, devices, circuits, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired and advantageous for any given or particular application. Accordingly, the present invention is not to be limited to the above-described embodiments, but is intended to be limited only by the appended claims and equivalents thereof. 

What is claimed is:
 1. A double inlet blower wheel comprising: a plurality of blades, wherein each of the plurality of blades has at least one notch defined along a length thereof; a center disk having an outer diameter, wherein a plurality of slots are defined in the center disk and are disposed about a circumference thereof, wherein the plurality of slots extend a predetermined distance inwardly from the outer diameter of the center disk, wherein the at least one notch of each of the plurality of blades engages a respective one of said plurality of slots, wherein the center disk fully encapsulates each of the plurality of blades about a periphery of each of the plurality of blades, and wherein an edge of the plurality of blades defines a blower wheel outer diameter, wherein the outer diameter of the center disk is less than the blower wheel outer diameter; and a pair of inlet rings respectively securing opposing ends of each of said plurality of blades thereto.
 2. The double inlet blower wheel of claim 1, wherein the plurality of slots are equally spaced about a circumference of the center disk.
 3. The double inlet blower wheel of claim 1, wherein the plurality of blades are curved when viewed from an axis of rotation of the blower wheel.
 4. The double inlet blower wheel of claim 1, wherein the center disk further comprises a support disk operably coupled to a central region thereof, wherein support disk provides a greater thickness of the center disk in the central region than at a periphery of the center disk, and wherein the support disk increases a rigidity of the center disk.
 5. The double inlet blower wheel of claim 1, wherein the center disk comprises a plurality of roll-over tabs respectively associated with each of the plurality of slots, wherein the plurality of roll-over tabs are configured to respectively encapsulate the plurality of blades about the periphery thereof.
 6. The double inlet blower wheel of claim 5, wherein the at least one notch in each of the plurality of blades comprises a V-shaped notch centered along the length thereof.
 7. The double inlet blower wheel of claim 6, wherein the plurality of slots further define an inner diameter of the center disk, wherein each of the plurality of blades further has a clearance notch, wherein the clearance notch generally opposes the V-shaped notch, wherein the clearance notch of each of the plurality of blades engages the inner diameter of the center disk, and wherein the plurality of roll-over tabs are configured to respectively engage the V-shaped notch of each of the plurality of blades.
 8. The double inlet blower wheel of claim 7, wherein the clearance notch is rectangular.
 9. The double inlet blower wheel of claim 1, wherein the at least one notch in each of the plurality of blades comprises one or more of a V-shaped notch and a clearance notch centered along the length thereof.
 10. A double inlet blower wheel, comprising: a plurality of blades, wherein each of the plurality of blades has at least one notch defined along a length thereof; a center disk having an outer diameter, wherein a plurality of slots are defined in the center disk and are disposed about a circumference thereof, wherein the plurality of slots extend a predetermined distance inwardly from the outer diameter of the center disk, wherein the at least one notch of each of the plurality of blades engages a respective one of said plurality of slots, wherein the center disk fully encapsulates each of the plurality of blades about a periphery of each of the plurality of blades, and wherein an edge of the plurality of blades defines a blower wheel diameter, wherein the outer diameter of the center disk is less than the blower wheel diameter, wherein the center disk further comprises a support disk operably coupled to a central region thereof, wherein support disk provides a greater thickness of the center disk in the central region than at a periphery of the center disk, and wherein the support disk increases a rigidity of the center disk; and a pair of inlet rings respectively securing opposing ends of each of said plurality of blades thereto.
 11. The double inlet blower wheel of claim 10, wherein the center disk comprises a plurality of roll-over tabs respectively associated with each of the plurality of slots, wherein the plurality of roll-over tabs are configured to respectively encapsulate the plurality of blades about the periphery thereof.
 12. The double inlet blower wheel of claim 11, wherein the at least one notch in each of the plurality of blades comprises a V-shaped notch centered along the length thereof.
 13. The double inlet blower wheel of claim 12, wherein the plurality of slots further define an inner diameter of the center disk, wherein each of the plurality of blades further has a clearance notch, wherein the clearance notch generally opposes the V-shaped notch, wherein the clearance notch of each of the plurality of blades engages the inner diameter of the center disk, and wherein the plurality of roll-over tabs are configured to respectively engage the V-shaped notch of each of the plurality of blade.
 14. The double inlet blower wheel of claim 10, wherein the at least one notch in each of the plurality of blades comprises one or more of a V-shaped notch and a clearance notch centered along the length thereof.
 15. The double inlet blower wheel of claim 10, wherein the plurality of slots are equally spaced about a circumference of the center disk.
 16. The double inlet blower wheel of claim 10, wherein the plurality of blades are curved when viewed from an axis of rotation of the blower wheel.
 17. A double inlet blower wheel, comprising: a plurality of blades, wherein each of the plurality of blades comprises a V-shaped notch and a clearance notch centered along a length thereof, wherein the clearance notch generally opposes the V-shaped notch; a center disk having an outer diameter, wherein a plurality of slots are defined in the center disk and are disposed about a circumference thereof, wherein the plurality of slots extend a predetermined distance inwardly from the outer diameter of the center disk therein defining an inner diameter of the center disk, wherein the center disk comprises a plurality of roll-over tabs respectively associated with each of the plurality of slots, and wherein each of the plurality of blades engages a respective one of said plurality of slots, wherein the clearance notch of each of the plurality of blades engages the inner diameter of the center disk, and wherein a plurality of roll-over tabs are configured to respectively engage the V-shaped notch of each of the plurality of blade, therein fully encapsulating the plurality of blades about a periphery thereof, wherein an edge of the plurality of blades defines a blower wheel outer diameter, wherein the outer diameter of the center disk is less than the blower wheel outer diameter, and wherein the center disk further comprises a support disk operably coupled to a central region thereof, wherein support disk provides a greater thickness of the center disk in the central region than at a periphery of the center disk, and wherein the support disk increases a rigidity of the center disk; and a pair of inlet rings respectively securing opposing ends of each of said plurality of blades thereto.
 18. The double inlet blower wheel of claim 17, wherein the clearance notch is rectangular. 